Prevent Cassette Door Leaking and Rust

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SUIET Hacks removed the cassette door when removing Hymer's "factory installed" butane torch (a story for another time). We were disappointed to find the ProMaster side was rusting on our one-month old Aktiv 2018. Additionally there was a large gap letting water into the cabin. There were a number of design root causes:

1. Hymer-added an "eave" to Thetford's standard cassette door assembly and it props to door assembly away from the ProMaster side and leaves a gap for water to ingress. The gap was so large we could slide folded paper between the door flange and the ProMaster's side.
2. Unrelated to #1, Hymer did not paint the edges of the hole they cut through the ProMaster's side.
3. Unrelated to #1 and #2, Hymer left metal burrs in the area, so the fasten cassette flange pressed the metal and scratched the paint off, resulting in more rust.

Kathy was more than a little disappointed and shocked that SUIET Hacks, LLC was painting the side of her brand-new Aktiv. Is rust covered under our warranty? As usual Hymer has not responded to our emailed report and pictures.

Installation takes about 10 minutes and costs less than $3 (if you don't have to paint).

Special Tools:

• none

Parts

• 3/8-inch x 3/16 Frost King rubber weather stripping

Installation

• Remove the cassette door assembly and eave (10 screws).
• Inspect for rust and burrs, repair if needed.
• Attach one strip of weather stripping around the entire ProMaster-facing side of the cassette door assembly flange.
• Attach one strip of weather stripping on the entire ProMaster-facing side of the black ABS "eave."
• Reassemble by inserting and nearly tightening all screws
• Snug tight all screws in a staggered star pattern.